Optical Fiber Preform With Improved Air/Glass Interface Structure

ABSTRACT

An optical fiber preform comprising a plurality of longitudinal air holes is subjected to a thermal treatment (i.e., heating), coupled with the application of a compressive force on either end of the heated preform to compress the entire preform structure a predetermined amount. The thermal compression treatment has been found to smooth any roughened glass surfaces and heal microcracks that may have formed during the preform fabrication process, essentially “knitting” the glass material back together and forming a preform of improved quality over the prior art microstructured preforms.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is divisional of U.S. application Ser. No. 11/644,621,filed Dec. 22, 2006 and issued a Notice of Allowance on Jul. 26, 2010.

TECHNICAL FIELD

The present invention relates to an improved quality optical fiberpreform and, more particularly, to a microstructured preform formedusing a thermal compression technique to improve the quality of theair/glass interfaces within the microstructured configuration.

BACKGROUND OF THE INVENTION

Several types of optical fibers require the formation of longitudinalair holes within the preform from which the fiber is ultimately drawn.For example, microstructured optical fibers are formed from preformsthat include longitudinally disposed air holes. Polarization-maintainingoptical fiber preforms include longitudinal holes that are subsequentlyfilled with stress rods to control the propagating polarization state inthe drawn fiber. These longitudinal holes may be formed in optical fiberpreforms through a variety of conventional techniques including, but notlimited to, drilling, piercing, casting or extruding.

The quality of the air/glass interfaces within optical fiber preformsincluding longitudinal holes is often problematic due to surfaceroughness, where the roughness may be a result of several differentsources. For example, the glass surface may be damaged from a machiningprocess used to drill the longitudinal holes, the nascent surface frommolds and rods used in casting, or damage from de-molding operationsassociated with conventional Sol-gel casting.

Regardless of the source of the roughness, the roughness and associatedmicrocracks have been found to attribute to increased signal loss in thedrawn optical fiber. In particular, the presence of roughness andmicrocracks within a microstructured optical fiber (or any fiberincluding longitudinally disposed components, such as glass rods) leadsto loss associated with optical signal scattering and non-uniform holesize in the drawn fiber. Further, if the preform is etched in ahydrofluoric (HF) solution (a conventional processing step), thepresence of the etchant will allow for propagation of thealready-present microcracks. Pressurization of the preform during drawwill also allow for the microcracks to propagate. If the microcrackpresence is severe enough, the internal air holes will connect,destroying the fiber geometry and limiting the ability to form fiberswith relatively large air/fill fraction configurations (e.g., >50%).

With respect to polarization-maintaining optical fiber, surfaceroughness has been found to contribute to the formation of bubbles anddistortion of the stress rods, both of which degrade the polarizationcross-talk parameter. In stretching preforms made with drilled andpolished holes, the surface defects become extended in length, resultingin a defect known as “fiber air lines”, which degrade the ability toperform fusion splices within the drawn fiber.

In light of all of the above, a need remains in the art for an opticalfiber preform well-suited for configurations including longitudinal airholes, such as microstructured fiber preforms orpolarization-maintaining optical fiber preforms.

SUMMARY OF THE INVENTION

The need remaining in the prior art is addressed by the presentinvention, which relates to an improved quality optical fiber preformand, more particularly, to a microstructured preform formed using athermal compression treatment, prior to drawing the fiber, to improvethe quality of the air/glass interfaces within the microstructuredconfiguration.

In accordance with the present invention, an optical fiber preformcomprising a plurality of longitudinal air holes is subjected to athermal treatment (i.e., heating), coupled with the application of acompressive force on either end of the heated preform to compress theentire preform structure a predetermined amount. Following thecompression, the preform may be stretched and then, ultimately, drawninto fiber. The thermal treatment has been found to smooth any roughenedglass surfaces and heal microcracks that may have formed during thepreform fabrication process, essentially “knitting” the glass materialback together and forming a preform of improved quality over the priorart microstructured preforms.

In one embodiment of the invention, a positive or negative air pressuremay be forced (blown) through the longitudinal air holes during thethermal treatment to either increase or decrease the diameter of the airholes running along the longitudinal extent of the preform.

Other and further embodiments and features of the invention will becomeapparent during the course of the following discussion and by referenceto the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings,

FIG. 1 is an isometric view, and FIG. 2 a cut-away top view, of anexemplary fiber preform including a plurality of longitudinal air holesthat may be subject to rough surfaces and the formation of microcracksduring preform fabrication;

FIG. 3 contains a side view of a conventional prior art microstructuredoptical preform, with FIG. 3( a) illustrating the preform prior toperforming a preform stretching operation and FIG. 3( b) illustratingthe preform after the preform stretching operation;

FIGS. 4-6 illustrate an exemplary process of the present invention forthermally treating a preform to reduce rough surfaces and microcracks;

FIG. 7 contains a side view of a microstructured optical preform, withFIG. 7( a) illustrating the preform prior to the inventive thermaltreatment, and FIG. 7( b) illustrating the preform subsequent to theinventive thermal treatment;

FIG. 8 illustrates a comparison of microstructured preforms subjected toan etch in hydrofluoric acid, with FIG. 8( a) illustrating aconventional, prior art preform and FIG. 8( b) illustrating a preformformed in accordance with the present invention;

FIG. 9 illustrates cross-sectional images of microstructured preformshaving a relatively large air/fill fraction, formed in accordance withthe present invention; and

FIG. 10 is a graph of hole size as a function of preform diameter,illustrating the change in air hole size as a function of preformdiameter.

DETAILED DESCRIPTION

FIG. 1 illustrates, in an isometric view, a typical microstructuredprior art optical fiber preform 10. A cut-away top view of preform 10 isshown in FIG. 2. Microstructured preform 10 includes an inner region 12and an outer region 14. Inner region 12 is formed of a suitable opticfiber material (such as, for example, silica) and includes a pluralityof longitudinal air holes 18. The particular arrangement of FIG. 1 alsoincludes a hollow core region 20. For embodiments where optical preform10 is utilized to fabricate polarization-maintaining fiber, inner region12 may further comprise a plurality of glass rods 22 disposed withinselected air holes 18, used to provide longitudinal mechanical strengthto the arrangement. Outer region 14 is utilized as a sleeve to supportthe structure of inner region 12. The remainder of the followingdiscussion will simply reference to the preform as a “microstructuredpreform”. It is to be understood that this term equally applies topolarization-maintaining optical preforms, which are also formed toinclude longitudinal air holes during process and thus create the samesurface roughness problems.

As mentioned above, there exist various techniques (well known in theart) to form the plurality of longitudinal air holes 18 within preform10. These techniques include, but are not limited to, drilling, etching,the use of molds and casting forms, and the like. The quality of thelarge number of air/glass interfaces within optical fiber preformsincluding longitudinal holes is often problematic due to surfaceroughness, where the roughness may be a result of several differentsources. Many of these microstructured optical performs also includemicrocracks, where these microcracks are known to propagate along aparticular air/glass interface as the preform is “stretched” at thebeginning of the fiber draw process. FIG. 3 contains a photograph of aconventional prior art microstructured optical preform (side view),where the illustration of FIG. 3( a) illustrates the preform prior tostretching. A number of microcracks (denoted as “M” in the illustration)are evident in this view. These microcracks are shown as being largerand more pronounced in the view of FIG. 3( b). which illustrates thesame optical preform—subsequent to the conventional stretchingoperation.

Moreover, if the preform is etched in an HF solution (a conventionalprocessing step, as mentioned above), the presence of the etchant willencourage the further propagation and/or enlargement of the microcracksalong a particular air/glass interface. Pressurization of the preformduring draw (another common fabrication environment) will also allow forthe microcracks to propagate/enlarge. If the microcrack presence issevere enough, the internal air holes will connect, destroying the fibergeometry and limiting the ability to form fibers with relatively largeair/fill fraction configurations (e.g., >50%). While the followingdiscussion will emphasize the ability of the inventive thermal treatmentprocess to eliminate microcracks, it is to be understood that in itsmost general application the method of the present invention is utilizedto reduce/eliminate surface roughness at the air/glass interfaces ingeneral, that is, to “heal” all of the various surface defectsassociated with the formation of longitudinal air holes.

FIGS. 4-6 illustrate an exemplary set of thermal processing steps thathave been found, in accordance with the present invention, to treat theair/glass interfaces within a microstructured optical fiber preform in amanner such that the surface roughness and microcracks are essentiallyeliminated, thus improving the quality of the optical fiber ultimatelydrawn from the microstructured preform. In particular, and as discussedin detail below, a novel controlled compression process has been foundto “heal” the damage created by the preform fabrication process.

Referring to FIG. 4, the thermal treatment of the present inventionbegins with attaching a pair of glass handles 30, 32 to opposite ends ofa microstructured optical fiber preform, such as preform 10 illustratedabove. Once handles 30 and 32 have been attached, the arrangement ismounted in a lathe (not shown) or similar arrangement capable ofsupporting the arrangement during processing. A plasma torch 34 is usedto heat preform 10 to a temperature at which the glass material willflow under stress. For example, a temperature of about 2000° C. has beensuitable for this purpose. It is to be understood that various otherconventional heat sources, such as an oxy-hydrogen torch or furnace maybe used in performing the method of the present invention.

When the temperature reaches the desired glass flow temperature, acompressive force F_(c) is applied against handles 30 and 32, as shownin FIG. 5. Compression is preferably accomplished while also rotatingpreform 10 within a lathe and traversing plasma torch 34 along therotating preform. The traverse velocity may be, for example, about 2cm/min. Along with the transversal heating, handles 30 and 32 aresimultaneously moved closer together until the desired amount ofcompression is obtained, where the diameter of the preform may be usedas the measure of sufficient compression. Referring to FIGS. 4 and 5, anincrease in the diameter of preform 10 is illustrated as diameter d_(i)for the “initial” diameter of preform 10 (for example, 35 mm) in FIG. 4,and d_(c) as the “compressed” diameter of preform 10 (for example, 42mm) in FIG. 5. It has been found that performing compression during thisinitial heating step will knit together any internal microcracks, andheal surface roughness (i.e., air/glass interfaces along longitudinalholes) through viscous flow.

Following the compression, preform 10 may be stretched prior to beingdrawn down into fiber (as in conventional preform fabrication), thisstep being illustrated in FIG. 6 with the “stretching force” illustratedby arrows F_(s). Again, preform 10 is rotated and heated with atransversal movement of, for example, plasma torch 34, during thestretching. The stretched diameter, denoted d_(s) may also be apredetermined value utilized to determine when the process is finished(for example, a stretched diameter d_(s) of 25 mm). Stretching may beperformed in a single pass, or with multiple passes. For the stretchingoperation, the velocity of plasma torch 34 can be controlled, in oneinstance, by utilizing a feedback signal that monitors the currentdiameter of the preform.

As mentioned above, it is possible to modify the diameter of thelongitudinal air holes during the thermal treatment process of thepresent invention. In particular, during either the compression step orthe stretching step (or both), a gas may be flowed through the airholes. A positive pressure flow will increase the diameter of the airholes, while a negative pressure flow will decrease the diameter of thelongitudinal air holes.

FIG. 7 contains actual photographs illustrating the improvement inpreform quality associated with the thermal compression process of thepresent invention. FIG. 7( a) is a photograph (side view) of anexemplary microstructured preform prior to thermal treatment. The darkerregions correspond to the longitudinal air holes, while the brightregions are the silica material of the preform. Similar to theillustrations of FIG. 3, various “microcracks” are evident in thephotograph of FIG. 7( a). Subsequent to the thermalcompression/stretching process of the present invention, thesemicrocracks have been virtually eliminated, as shown in the photographof FIG. 7( b).

One prior art technique for increasing the diameter of the air holes isto subject the preform to an etch in an acidic solution, such ashydrofluoric acid. However, the HF etch operation has been found toincrease the severity of the already-present microcracks within thepreform. FIG. 8( a) illustrates an exemplary prior art microstructuredpreform that has been subjected to an HF etch process. The HF etch ofthis prior art preform shows several large defects that can beattributed to preferential etching along the microcracks of the originalpreform. In contrast, the use of the thermal treatment process of thepresent invention prior to an HF etch will minimize/eliminate themicrocracks and result in an improved quality preform, as evident by thephotograph of FIG. 8( b).

The thermal treatment of the present invention, as mentioned above andindicative from the illustrations of FIGS. 7( b) and 8(b), yields anessentially uniform surface finish along each of the air/glassinterfaces within a microstructured preform. As a result, amicrostructured preform with a relatively high air/fill fraction can becreated, as shown in FIG. 9. For example, FIG. 9( a) contains across-sectional image of a microstructured preform with a 70% air/fillfraction. The image of FIG. 9( b) is associated with an 85% air/fillfraction and FIG. 9( c) with a 99% air/fill fraction. Such largefractions would be difficult, if not impossible, to create without thethermal compression treatment of the present invention. Each of theimages illustrates that the hole sizes are uniform throughout thecross-section, indicating that the thermal treatment does not alter ordistort the topology of the holes.

One concern with the use of a thermal compression process is that thehigh temperature of the plasma torch may cause some of the holes tocollapse or distort. FIG. 10 contains a plot associated with a preformthat was first compressed from a diameter of 35 mm to a diameter of 42,and then stretched to 15 mm. The air hole sizes were measured as afunction of the preform diameter. The hole size shows a consistentlylinear dependence on the preform diameter, indicating that there is nosignificant change in the relative hole size within the microstructuredpreform during the thermal treatment process of the present invention.

It is to be understood that there exist various modifications that maybe made to the inventive thermal treatment process including, but notlimited to, the diameter achieved during compression, the compressiveand tensile applied forces, the air-fill fraction, and the like. Indeed,the spirit and scope of the present invention is intended to be limitedonly by the claims appended hereto.

1. A microstructured optical fiber preform exhibiting minimal air-glassinterface imperfections formed by: heating a selected longitudinalportion of the microstructured optical fiber preform; and longitudinallycompressing the heated, selected portion of said preform using a forcesufficient to heal air-glass interface imperfections along themicrostructured optical fiber preform.
 2. An optical fiber preform asdefined in claim 1 wherein the preform exhibits an air/fill fractiongreater than 75%.
 3. An optical fiber preform as defined in claim 1,wherein the preform comprises a polarization maintaining optical fiberpreform.
 4. An optical fiber preform as defined in claim 1 wherein thepreform further comprises a plurality of longitudinal air holes.
 5. Anoptical fiber preform as defined in claim 4 wherein the preform furthercomprises a plurality of glass rods extending through selected ones ofthe plurality of longitudinal air holes.
 6. A microstructured opticalfiber exhibiting minimal air-glass interface imperfections formed by: a)heating a selected longitudinal portion of the microstructured opticalfiber preform; b) longitudinally compressing the heated, selectedportion of said preform using a force sufficient to heal air-glassinterface imperfections along the microstructured optical fiber preform;c) longitudinally stretching the compressed, healed preform of step b)to a diameter suitable for subsequent drawing of the preform into amicrostructured optical fiber; and d) drawing the preform of step c)into a microstructured optical fiber.